ESAB Spool Gun User manual

Brand: ESAB

Model: Spool Gun

Category: Grass trimmers

Type: User manual

FORM NO. 0056-1867 EFFECTIVE MAY, 2001

Modular Spool Gun for MIG Welding

Operating and Safety Instructions

For Your Safety....

PLEASE READ CAREFULLY!

 IMPORTANT 

Spool Gun

Operating and Safety Manual

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

TABLE OF CONTENTS

1. Introduction.................................................................................................3

2. Safety Instructions........................................................................................5

3. Product Description......................................................................................9

4. Installation..................................................................................................10

1. Connecting Spool Gun to Power Source...........................................10

2. Installing Wire Spool.........................................................................11

3. Wire speed adjustment.....................................................................13

5. Maintenance..............................................................................................14

1. Controls............................................................................................14

2. Changing drive rolls..........................................................................15

3. Changing outlet liner........................................................................16

4. Troubleshooting Check List...............................................................17

6. Technical Data Sheet..................................................................................18

7. Electric Connections...................................................................................19

8. Spare Parts Lists.........................................................................................20

9. Warranty....................................................................................................23

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

Introduction

The Spool Gun is the best solution for situations where the power source can not be brought close

enough to your the work. The Firepower Spool Gun is a professional MIG gun suitable for welding

carbon steel, stainless steel or aluminum, using solid wire and also for flux cored wire. Wire is

driven by a DC electric motor in the gun, wire speed is controlled by an adjustable potentiometer

mounted in the base of the gun handle.

 WARNING: Before attempting to connect, operate or adjust this product, please read this

instruction manual completely. Following these instructions carefully will facilitate the use of the

spool gun.

The 180 Amp Spool Gun

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

Introduction

This User’s Guide provides pertinent informa-

tion needed to safely and effectively use your

Firepower Spool Gun. It gives instructions on

set-up, installation and actual use of your

Firepower Spool Gun.

Safety Profile

Tradesmen respect the tools and equipment

with which they work. They are also aware

that tools and equipment are dangerous if

used improperly or abused.

NOTE: Read this guide prior to using

your Spool Gun. It enables you to do a bet-

ter and safer job. You will also learn the Spool

Gun’s application, limitations, and the specific

potential hazards peculiar to welding.

Safety Information

The following safety information is provided

to you as a guideline. Use it to operate your

new Firepower Spool Gun under the safest

possible conditions. Any equipment that uses

electrical power is potentially dangerous to

use when the safety or safe handling instruc-

tions are not known and/or are not followed.

This safety information gives you the neces-

sary information for safe use and operation.

WARNING

Items in this manual that significantly affect

safety are identified with the following head-

ings. Please read and understand this manual.

Pay special attention to items identified with

these headings.

WARNING – Means there is a poss-

ibility of injury or death to you or others.

CAUTION – Means there is the

possibility of damage to the Firepower

Spool Gun or other property.

NOTICE – Indicates point of interest for

more efficient and convenient installation or

operation.

Read all Safety and Warning Instructions

Carefully before attempting to install, operate

or service this welding unit. Your failure to

comply with the instructions could result in

personal injury and/or property damage.

 IMPORTANT 

RETAIN THESE INSTRUCTIONS FOR YOUR

FUTURE REFERENCE.

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

Safety Symbols

Familiarize yourself with the warning symbols

listed on the following pages. These symbols

identify important safety messages in this

manual. When you see one of these symbols,

be alert to the possibility of personal injury and

carefully read the message that follows.

ndicates that the possibility of ELECTRIC

SHOCK exists during the operation of the

step(s) that follow.

Indicates that the possibility of FIRE HAZ-

ARD exists during the step(s) that follow to

protect against eye damage and burns due

to flash hazard.

Indicates that the HELMET MUST BE WORN

during the step(s) that follow to protect

against eye damage and burns due to flash

hazard.

Indicates that the POSSIBILITY OF TOXIC

GAS hazard exists during operation of the

step(s) that follow.

Indicates that the POSSIBILITY OF BEING

BURNED by hot slag exists during operation

of the step(s) that follow.

Indicates that EYE PROTECTION SHOULD

BE WORN to protect against flying debris in

the following step(s).

Indicates that the POSSIBILITY OF INJURY

OR DEATH exist due to improper handling

and maintenance of compressed gas cylin-

ders or regulators.

ELECTRIC SHOCK CAN KILL! Reduce the

risk of death or serious injury from shock:

Read, understand and follow the following

safety instructions. Additionally, make cer-

tain that anyone else who uses this welding

equipment, or who is a bystander in the

welding area, understands and follows these

safety instructions as well.

FIRE OR EXPLOSION CAN CAUSE DEATH,

INJURY AND PROPERTY DAMAGE! Reduce

the risk of death, injury or property damage

from fire or explosion. Read, understand and

follow the following safety instructions.

Additionally, make certain that anyone else

who uses this welding equipment, or who is

a bystander in the welding area, understands

and follows these safety instructions as well.

Remember, welding by nature produces

sparks, hot spatter, molten metal drops, hot

slag and hot metal parts that can start fires,

burn skin and damage eyes.

ARC RAYS CAN INJURE EYES AND BURN

SKIN! Reduce the risk of injury from arc

rays. Read, understand and follow the fol-

lowing safety instructions. Additionally,

make certain that anyone else who uses this

welding equipment, or who is a bystander in

the welding area, understands and follows

these safety instructions as well.

FUMES, GASES AND VAPORS CAN CAUSE

DISCOMFORT, ILLNESS AND DEATH!

Reduce the risk of discomfort, illness or

death. Read, understand and follow the fol-

lowing safety instructions. Additionally,

make certain that anyone else who uses this

welding equipment, or who is a bystander in

the welding area, understands and follows

these safety instructions as well.

IMPROPER HANDLING AND

MAINTENANCE OF COMPRESSED GAS

CYLINDERS AND REGULATORS CAN

RESULT IN SERIOUS INJURY OR DEATH!

Reduce the risk of injury or death from com-

pressed gases and equipment hazards. Read,

understand and follow the following safety

instructions. Additionally, make certain that

anyone else who uses this welding equip-

ment, or who is a bystander in the welding

area, understands and follows these safety

instructions as well.

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

Health Hazards

The welding process can be hazardous to your

health. Therefore, follow these precautions:

1. ALWAYS wear protective clothing without

pockets and cuffs. Wear a helmet, gloves

and shoes with an insulating sole.

2. ALWAYS use a welding mask or helmet

with the properly tinted protective glass in

the shade adequate to the welding opera-

tion being performed and to the current

intensity.

3. Make certain that bystanders in the weld-

ing area are also following these precau-

tions.

4. ALWAYS keep the welding mask glass

clean. Replace it if it is cracked or chipped.

5. NEVER weld in a damp area or come in

contact with a moist or wet surface when

welding.

6. If the welding area lacks proper ventilation,

use fume extractors.

7. Clean the welding pieces of solvents or

grease which develop toxic gases when

exposed to heat.

Electric Shock

WARNING Electric Shock Can Kill!

Reduce the risk of death or serious injury

from shock. Read, understand and follow

ALL safety instructions. Be sure that

everyone who uses this welding equip-

ment or who is a bystander in the weld-

ing area understands and follows ALL

safety instructions as well.

WARNING Electric Shock Can Be Fatal.

A person qualified in First Aid techniques

should ALWAYS be present in the work-

ing area. If a person is unconscious and

electric shock is suspected, DO NOT

touch the person if he or she is in contact

with electric wires or touch leads.

Disconnect power from the machine,

then use First Aid. Use dry wood or other

insulating materials to move cables, if

necessary, away from the person.

1. Never touch or come in physical contact

with any part of the input current circuit

and welding current circuit.

2. Frequently check that the input cable and

plug are in good condition.

3. Make sure that the welder is disconnect-

ed from the main power supply BEFORE

attempting any repairs, opening the side

panels of the machine or repairing the

input cable.

4. Fit the main line BEFORE the distribution

outlet, with a three-pole switch with ade-

quate delayed fuses (check the character-

istics plate for fuse values).

5. DO NOT weld with cables, torch or earth

clamp in poor shape.

6. DO NOT coil the torch or the earth

cables around your body.

7. DO NOT point the welding torch against

yourself or against bystanders.

8. Should you feel the slightest electrical

shock, STOP welding IMMEDIATELY!

DO NOT use the welder until the fault is

found and resolved.

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

General Welding

Safety Instructions

WARNING Welding processes of any

kind can be dangerous not only to the oper-

ator but to any person situated near the

equipment, if safety and operating rules are

not strictly observed.

Personal Protection

1. WARNING Wear closed, non-flam-

mable protective clothing, without pock-

ets or turned up trousers.

2. WARNING Wear a non-flammable

welding helmet to shield the neck, face

and sides of the head. Keep the protec-

tive lens clean. Replace the protective

lens if broken or cracked. Position a

transparent glass between the lens and

the welding area. Weld in a well ventilat-

ed area that does not open into other

working areas.

3. WARNING Never look at the arc

without proper protection for the eyes.

4. WARNING Thoroughly clean metal

of rust or paint to avoid producing harm-

ful fumes. Parts degreased with a solvent

must dry before welding.

5. WARNING Never weld on metals or

coated metals containing zinc, mercury,

chromium, graphite, lead, cadmium or

beryllium unless the operator and the

people standing in the same area use an

air-supplied respirator.

Safety Instructions

For your safety, BEFORE connecting the power

source to the line, follow these instructions:

1. Insert an adequate two-pole switch,

equipped with time-delay fuses, before

the main outlet.

2. Make the single-phase connection with a

two-pole plug compatible with the above

mentioned socket.

3. The two wires of the two-pole input

cable are used for the connection with

the single-phase line. The yellow/green

wire is for the compulsory connection to

the ground in the welding area.

4. When working in a confined space, keep

the power source outside the welding

area and fix the ground cable to the

workpiece. Never work in a damp or wet

area.

5 DO NOT use damaged input or welding

cables.

6. WARNING NEVER operate the

power source without its panels in place.

This could cause serious injury to the

operator and could damage the equip-

ment.

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

Fire Prevention

Welding operations use fire or combustion as a

basic tool.

1. The work area MUST have a fireproof

floor.

2. Work benches or tables used during

welding operations MUST have fireproof

tops. DO NOT weld on wooden work

benches.

3. Use heat-resistant shields or other

approved material to protect nearby walls

or unprotected flooring from sparks and

hot metal.

4. Keep an approved fire extinguisher of the

proper size and type in the work area.

Inspect it regularly to ensure that it is in

proper working order. Know how to use

the fire extinguisher.

5. Remove all combustible materials from

the work site. If you can not remove

them, protect them with fireproof covers.

WARNING NEVER perform welding

operations on a container that has held toxic,

combustible or flammable liquids or vapors.

NEVER perform welding operations in an

area containing combustible vapors, flamma-

ble liquids or explosive dust.

Ventilation

WARNING Ventilate welding work areas

adequately. Maintain sufficient air flow to

prevent accumulation of explosive or toxic

concentrations of gases. Welding operations

using certain combinations of metals, coat-

ings and gases generate toxic fumes. Use

respiratory protection equipment in these cir-

cumstances. BEFORE welding, read and

understand the Material Safety Data Sheet

for the welding alloy.

Electromagnetic Compatibility

BEFORE installing a MIG power source,

inspect the surrounding area checking the

following points:

1. Make sure there are no other power sup-

ply cables, control lines, telephone cables

or other devices close to the power

source.

2. Make sure that telephones, televisions,

computers or other control systems are

not in the working area.

3. People with pace-makers or hearing aides

should keep far from the power source.

In particular cases, special protection

measures may be required.

Reduce interference by following these sug-

gestions:

1. If there is interference in the power

source line, mount an E.M.T. filter

between the power supply and the

power source.

2. Shorten the output cables of the power

source, keep them together and connect-

ed to ground.

3. Securely fasten the panels of the power

source in place after performing mainte-

nance.

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

3. Product Description

Drive roll pressure

adjustment screw

Wire Spool

Wire tension

adjustment nut

Drive Rolls

Trigger

Drive roll pressure release lever

Nozzle

Wire Speed Adjustment

(Potentiometer)

Cable

Figure 1

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

4. Installation

The manufacturer will not be responsible for damages caused by incorrect installation. Any

service required due to incorrect installation will not be covered by the warranty.

4.1. Connecting Spool Gun to the Power Source

The Spool Gun is provided with two connectors:

• Connection for power cable, gas hose, liner, and trigger.

• 6 pin connector for motor power and wire speed control.

1. Before connecting the Spool Gun,

switch off the power source.

2. Connect spool gun Euro Connect

adapter to power source terminal and

rotate the lock ring clockwise until it is

firmly locked. (Do not over tighten)

3. Connect spool gun 6 pin connector to

power source terminal and rotate the

lock ring clockwise until it is firmly

locked. (Do not over tighten)

4. Once the connections have been made

properly, switch the power source on.

For more information please refer to spool

gun electric schematic (see page 19).

Figure 2

Figure 3

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

1. Before operating on the torch, switch off

the welder.

2. Remove nozzle.

3. Make sure that liner and contact tip

match with diameter of welding wire.

4. Remove any burrs or sharp points from

end before fitting into torch.

5. Open the wire spool cover and insert

the spool into spool shell (wire feeds

from top).

6. Adjust the friction nut on the spool shaft

to find the correct wire tension

4.2. Installing Wire Spool

For the choice of right contact tip and wire please refer to spool gun data sheet (see par.6.)

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

7. Thread wire into inlet liner

8. Push and hold red drive roll pressure

release lever

9. Thread wire to the middle of drive rolls

10. Release red lever

11. Replace the spool cover and switch the

power source on

12. Turn the wire speed adjustment to

minimum wire speed (see page 13 )

13. Press gun trigger to feed wire through

outlet liner and out the end of the

contact tip 2” (50mm).

WARNING — Never place finger over

end of gun. Wire may be driven through

finger

14. Install nozzle

15. Pressing gun trigger to feed wire, adjust

the drive roll pressure to provide smooth

wire travel without crushing the wire.

16. Cut off wire

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

4.3. Wire speed adjustment

1. Turn wire speed adjustment to minimum

wire speed

2. Start welding by pressing the trigger.

3. Increase wire speed to achieve the

desired arc by turning the wire speed

adjustment clockwise.

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

5. Maintenance

5.1 Controls

Before you maintain or replace spool gun

parts, turn the power source off.

Replace contact tip if hole is enlarged or

deformed. Always make sure to use the

correct diameter for the wire

Replace liner if hole is obstructed. Smooth

head of liner.

Periodically clean inside of nozzle and holes of

gas diffuser. Use an anti-spatter spray.

Periodically clean drive rolls.

Check condition of cable. Do not make

temporary repairs. Repairs should only be

made by qualified personnel.

Do not bend cables and hoses too tightly, to

avoid damage that may prevent gas from

flowing freely.

Repairs must be done only by skilled and

qualified personnel.

Used parts should be recycled in a proper way,

meeting the local requirements.

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

1. Be sure to select replacement drive rolls

to match the wire diameter to be used.

NOTE that the lower drive roll is slotted

for the key.

2. Before removing the transparent drive

roll cover, turn off the power source.

3. Remove the transparent drive roll cover.

4. Relieve pressure on the drive rolls by

pressing down the red lever.

5. Changing upper drive roll: Remove

screw and washer and lift out the drive

roll. Slide the new drive roll onto shaft

and secure with washer and screw.

6. Changing lower drive roll: Remove

screw and washer and lift out the drive

roll. (NOTE - the key will normally come

out with the drive roll, be careful not to

lose the key.) Place the key in the shaft

slot and slide the new drive roll onto the

shaft. Secure with washer and screw.

7. Reinstall the transparent drive roll cover.

5.2. Changing drive rolls

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

5.3. Changing outlet liner

1. Remove the gas nozzle and the contact

tip from the gun tube

2. Pull the liner out of the gun tube

3. Make tip of liner round before fitting

into torch. NO SHARP EDGES.

4. Carefully insert the new liner into the

gun tube of the torch.

5. Install the contact tip and the gas nozzle

onto the end of the gun tube

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

5.4. Troubleshooting Check List

Incorrect drive rolls

pressure

Drive rolls turn but wire

will not feed or wire

feeding is rough

Incorrect drive rolls

Be sure the wire diameter

being used is stamped on

drive rolls. Replace drive rolls

if necessary

Check and correct drive roll

pressure. Turn pressure

adjusting screw clockwise,

enough to prevent slipping.

(see page 11)

Worn or dirty drive rolls

Clean or replace drive rolls

(see page 15)

Incorrect wire spool friction

Adjust the friction nut on the

spool shaft to find the correct

wire tension (see page 11)

Worn or dirty outlet liner

Clean or replace liner (see

page 16)

Rusty or dirty wire Replace wire (see page 11)

Partially flashed, melted or

improper size contact tip

Replace contact tip

Variable arc

Contact tip worn or

incorrect size

Replace contact tip

Incorrect wire feeder

speed

Adjust wire speed by turn-

ing pot ring clockwise (to

max) or counter-clockwise

(to min). (see page 13)

Trouble

Possible cause

Remedy

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

6. Technical Data Sheet

WELDING PARAMETERS

Welding current 150 A

Duty cycle 60 %

Cooling Gas

Power cable size 16 mm

Gas Argon - 100%

CONSUMABLES

Gas Diffusor TW 1

Gas Nozzle diameter 1/2"

Contact tip diameter as required

WIRE FEEDER

Voltage supply 24 V DC

Power 16 W

Average current draw 1-15 A

RPM (motor) 6000 RPM

Gear ratio 1:20

RPM (drive roll) 300 RPM

Wire feeder speed

Adjustable

1kOhm potentiometer

Max wire feeder speed

780 in./min.

(20m/min.)

.030" –.040"

(.08 – 1.0mm )

Maximum spool size

Diameter: 4” (100mm)

Width: 1.75"(45mm)

Overall dimensions

Length: 360mm (14.2”)

Width: 90mm (3.5”)

Height: 195mm (7.7”)

Net Weight (without spool) 2.5 lb. (1.15 kg)

OPTIONS

.023" (0.6mm)

Wire diameters for standard drive rolls

Drive rolls for steel and flux core wire

Drive rolls for aluminum wire

.045" (1.2mm)

.030/.035" (0.8/0.9mm)

.045" (1.2mm)

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

7. Electric Connections

Six Pin Connector

Euro Connector

Two Wires for Torch Trigger

Torch Trigger

Wiring for MIG Spool Gun With Speed Regulation On The Handle

Firepower SPOOL GUN OPERATING AND SAFETY MANUAL

8. Spool Gun Spare Parts List

8.1 Table 1 – Gun Case

Ref # P/N Description

1 1444-0051 Gas Nozzle 1/2”

2 1444-0025 Contact Tip .023”

2 1444-0026 Contact Tip .030”

2 1444-0027 Contact Tip .035”

2 1444-0028 Contact Tip .040”

2 1444-0029 Contact Tip. 045”

2 1444-0030 Contact Tip. 045” Aluminum

3 1444-0080 Gas Diffuser

4 1444-0619 Insulator Torch Body

5 1444-1620 Red Teflon Liner

6 1444-1621 Neck Cover

7 1444-0622 Neck

8 1444-0623 0-Ring

9 1444-0624 Neck Screw

10 1444-0636 Block

11 1444-0637 O-Ring

12 1444-0638 Sleeve

13 1444-0639 Nut

14/15/16/18 1444-0640 Rolls Assembly Accessories

17 1444-0625 Set/Drive Roller for .023” Wire (Small)

17 1444-0626 Set/Drive Roller for .030” and .040 Wire Standard (Medium)

17 1444-0627 Set/Drive Roller for .030” and .040 Wire Aluminum (Medium)

17 1444-0628 Set/Drive Roller for .045” Wire Standard (Large)

17 1444-0629 Set/Drive Roller for .045” Wire Aluminum (Large)

19 1444-0630 Wire Feed (Ratio 1:20)

20 1444-0631 Kit Handle

21 1444-0632 Rubber Sleeve

22 1444-0641 Friction Spacer

23 1444-0642 Friction Nut

24 1444-0643 Spool Cover

25 1444-0644 Wire Guide

26 1444-0645 Drive Rolls Cover

27 1444-0646 Handle Screw

28 1444-0647 Switch Assembly

29 1444-0648 Trigger/Potentiometer Connection Cable

30 1444-0649 Potentiometer 1kOhm

31 1444-0650 Potentiometer Knob

8.2 Table 2 – Cable Assembly and Central Adapter

Ref # P/N Description

A 1444-0651 Complete Cable

B 1444-0652 Gas Hose

C 1444-0653 Current Cable 16mm

D 1444-0654 Control Cable

E 1444-0655 Back Box

F 1444-0656 Box Screw

G 1444-0657 Gun Plug Nut

H 1444-0658 Euro Central Adaptor Body

J 1444-0659 Connector

8.3 Table 2 – Accessories

Ref # P/N Description

1444-0660 20 Feet Power Cable Extension

To maintain the performance of your Spool Gun, use only original manufacturer’s suggested spare parts listed

above.

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ESAB Spool Gun User manual

Brand: ESAB

Model: Spool Gun

Category: Grass trimmers

Type: User manual

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ESAB Spool Gun User manual

ESAB Spool Gun User manual

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